Plans for the 2015 Invention Challenge Target Paul MacNeal August 9,

Target 2

Target Parts List ComponentMaterialOverall DimensionsQuantityDetail on Page Long Base Joist2 x 4 Douglas Fir (DF) Stud 40.9” long28 Short Base Joist2 x 4 DF Stud10” long18 Base Plate1” plywood46.75” x 10”19 Base Sills2 x 2 DF Stud35”; 7”; 7”; 5”; 5” long510 Candle Column Panels¾” plywood46.75” x 10”211 Candle Column Panels¾” plywood46.75” x 8.5”211 Candle Column corner posts 2 x 2 DF Stud45” long411 Top of Column plate¾” Plywood10” x 10”112 Candlewick Supports1 x 3 Pine board2.5” long212 Candle Column Connection Studs 2 x 2 DF Stud2”; 5”; 5” long311 Candlewick1 x 3 Pine board2” x 13.3”113 Flame Plate¾” Plywood8” x 13”113 Vertical Support2 x 4 DF Stud53.5”114 Column and Right Diagonal2 x 4 DF StudApprox. 64” with angled cuts214 Number 18 Plate1” Plywood36” x 54”115 T-nut¼”-20 T-nut 111 Screws#8 deck screws2.0” long, 2.5” long, 3.5” long142; 30; 5various ¼”-20 machine bolts with washers and nuts ¼”-20 bolt2” long (1); 4” long (5)6 setsvarious 3

Bill of Materials ItemSizeQuantityNotes 2 x 4 Douglas Fir (DF) Stud8 feet long4Straight and free of large knots 2 x 2 DF Stud8 feet long3Straight and free of large knots ¾” Plywood (AC Grade)4’ x 4’1Half of a full sheet 1” Plywood (AC Grade)4’ x 8’1 1” x 3” Pine board2’ long1Larger width works as well #8 Deck Screws2” long142+Cheaper by the box #8 Deck Screws2.5” long30+Maybe cheaper by the box #9 Deck Screws3.5” long3By some extras ¼” hex bolt2” long1 ¼” hex bolt4.0” long4 ¼” washers 178 used for centering the flame on the pivot bolt ¼” hex nut 5 ¼” T-Nut1 Latch set (male and female)Small1Manufacturer is Richelieu Item number BP 6032G found at OSH. #6 machine screw and nut1.5” long2 bolts and 2 nutsTo attach female latch to support Paint As needed if desired Heavy weights50 pounds each3To secure to ground 4

Assembly Instructions A.Cut all pieces per each detailed sheet (all dimensions are in inches) B.Attach 2 x 2 studs on top of base plate 1.Carefully mark where each sill should go (refer to Slide 16). 2.Install 2.5” long deck screws from below up into the 2 x 2 studs. C.Attach lower beams to base plate with screws every 6 inches 1.Line up base plate assembly to the three base joists (refer to Slide 17). 2.Install 2.5” long deck screws from above down into the 2 x 4 joists. D.Assemble candle column together using four plates and 2 x 2 studs in the four corners using multiple screws. 1.Install ¼” T-nut by drilling hole per manufacturer’s instructions in the Right Panel where shown (refer to Slide 11) and hammering the T-nut in from the far side (inside). 2.Attach corner posts to Front Panel and Back Panel using 2.0” deck screws as shown in Slide Attach three short 2 x 2 connection posts to the right panel using 2.0” deck screws as shown on Slide Attach left panel to front and back panels using 2.0” deck screws with approximately the same spacing as done before when attaching the corner posts. Make sure the tops of the panels are co-aligned. 5.Attach the right panel to the front and back panels using 2.0” deck screws. Make sure the connection posts are in the correct location. Make sure the tops of the panels are co-aligned. E.Assemble top of column and candlewick supports 1.Attach candlewick supports to top plate from the underneath using 2.0” deck screws approximately where shown in Slide Drill the ¼” hole through both supports where shown in Slide 19. 5

Assembly Instructions F.Attach top plate to column 1.Attach top plate to column using 2.0” deck screws in the four corners as shown in Slide Attach front panel to candlewick supports using two 2.0” deck screws. 3.Line drill the ¼” hole for the candlewick through the candlewick supports per Slide 20. G.Assemble the flame assembly 1.Attach the male latch piece to the candlewick using manufacturer’s screws where shown on Slide Align the flame and attach to the candlewick with four screws as shown. 3.Putty over the screw heads (if desired) H.Attach latch (female piece) to candlewick support 1.Use multiple ¼” washers to make sure the candlewick is centered between the candlewick supports when mounted on the ¼” bolt. 2.Create a spacer with two holes to achieve good alignment between the female latch piece with the male latch piece (refer to Slide 22). 3.Attach the female latch piece to the candlewick supports using #6 machine screws and nuts. It is best to mark the holes using the actual latch with the male and female parts together and the candle in the upright position. 4.Make sure the flame assembly falls down with a light “hit” on the flame, but not too light. Adjust latches if needed. I.Attach candle column to base plate using the 2.0” deck screws going into the 2 x 2 sills (refer to Slide 23). 6

Assembly Instructions J.Attach upright support on right side of base opposite from the candle column 1.Align the front face of the bottom of the upright support with the base sill (refer to Slide 24). 2.Line drill a ¼” hole through both 2 x 4 studs. 3.Attach the boards using a 4.0" long ¼” bolt, washers, and nut. K.Attach right diagonal to the upright support 1.Ensure upright support is vertical using a level or other device. 2.Using two people, hold the right side diagonal in position to verify that the surfaces of the upright support and the diagonal are flush at the top and that there is room at the base to attach to the diagonal to the base joist (refer to Slide 25). 3.If alignment looks good, clamp the bottom of the diagonal to the base joist. 4.Drive 2 or 3 3.5” long deck screws through the diagonal into the upright support. 5.Line drill a ¼” hole through both the right diagonal and the base joist. 6.Attach the boards using a 4.0" long ¼” bolt, washers, and nut. L.Attach diagonal to the candle column 1.Locate the diagonal and find the proper location for the hole to match to the existing T-nut (refer to Slide 26). 2.Drill the ¼” hole into the column diagonal. 3.Attach the column diagonal to the column using a 2” long ¼” bolt and washer. 4.Ensure that the column is vertical. 5.When the column is vertical, line drill a ¼” hole through both the column diagonal and the base joist. 6.Attach the boards using a 4.0" long ¼” bolt, washers, and nut. M.Attach Number “18” plate to the remainder of the target using approximately ” deck screws (refer to Slide 27) Call Paul MacNeal at (626) if there are any questions or concerns. 7

8 40.9” 2 places 10.0” Make from 2 x 4 Stud Long and Short Base Joists

9 10.0” 46.75” 9.0” Make from 1” Plywood Base Plate

10 5.0” 2 places 7.0” 35.0” Base Sills 2 places Make from 2 x 2 Stud

8.5” 2 places ” 10.0” 2 places 46.75” 4 places 3.5” 0.25” 3 places 0.75” 4 pl 45.0” 4 places 22.5” 1.5” 5.0” 2 pl 2.0” 4.25” 3.0” 5.25” 3.75” T-nut Front Back LeftRight Candle Column Panels, Corner Posts, and Connection Studs Make posts and connections from 2 x 2 Stud Make panels from ¾” Plywood

” 3.0” 0.75” 3.5” 4.0” 2.0” 2.5” Make candlewick supports from 1 x 3 Board Make top from ¾” Plywood Top Plate and Candlewick Supports

” 12.8” 1.63” 3.8” 0.75” 1” grid to create outline of flame Drill ¼” hole Make flame from ¾” plywood Make flame support from 1 x 3 board Flame Plate and Candlewick Mark centerline on flame

14 Make from 2 x 4 Stud Upright Support and Diagonals 53.5” Upright Support 63.75” Right Diagonal Column Diagonal ”

15 Draw the Centerline of Target on plate Number “18” Plate Make from 1” Plywood 18.5” 4.5” 36.0” 2 places 24.0” 2 places 5.0” 2 places 46.5” 10.9” 17.25” 21.0”

” 3 places 7.5” 2 places 0.75” Install 2.5” long deck screws from below approximately where shown Assembly Step B

17 Install 2.5” long deck screws from above down into 2 x 4 base joists approximately where shown Assembly Step C

18 Align corner posts to top edge of panel 22.5” 1.5” 4.25” 5.25” 3.75” T-nut Front Back LeftRight Assembly Step D 0.75” 4 pl 0.25” 3 places

” 0.75” 4.0” 2.0” 1.25” 1.0” ¼” drill through both walls Align candlewick supports to this edge Assembly Step E

20 Note: CAD model does not show the correct detail for this assembly step, but the screw locations are nearly correct 1.5” from top edge (typical) Assembly Step F Install 2.0” long deck screws approximately where shown

21 1.0” ¼” hole (ref.) Assembly Step G 1.75” * * Not shown to scale Install 2.0” long deck screws approximately where shown Latch apart

22 Spacer is to be sized once more details are known Female latch piece with rollers (see photos) The details of this installation may require modifications or special techniques. If you have issues contact Paul MacNeal. Assembly Step H Latch together Latch apart

23 Assembly Step I Install 2.0” long deck screws approximately where shown

24 Ensure front of 2 x 4 upright is flush with the base plate sill 0.5” Assembly Step J

25 Ensure these surfaces are flush to each other 0.5” Assembly Step K

26 Find the proper location for the diagonal. Locate the hole for the T-Nut. Drill the ¼” hole into the column diagonal 0.5” Assembly Step L

27 Ensure these surfaces are flush to each other Assembly Step M Install 2.0” long deck screws approximately where shown